Air cooler with water separator

ABSTRACT

An air cooler assembly includes an air cooler having an air inlet manifold, an air outlet manifold, and a heat exchanger core connected at a first end thereof to the air inlet manifold and at a second end thereof to the air outlet manifold. A water separator includes a chamber having a first end and an opposed second end, an air inlet proximate the first end and connected to the air outlet manifold, and an air outlet proximate the second end. A water outlet is formed in a bottom surface of the chamber, and a channel is positioned beneath the water outlet. A condensate outlet is positioned on a bottom surface of the channel. A helical blade has a first end and a second end, and is positioned within the chamber between the air inlet and the air outlet.

FIELD

Aspects of this invention relate generally to an air cooler with a waterseparator, and, in particular, to an air cooler with a water separatorthat includes a helical blade.

BACKGROUND

An air cooler, for example a charge air cooler, which may also bereferred to as an intercooler or an aftercooler, may be used on engines,such as diesel engines, to cool engine air that has passed through thecompressor (e.g., turbocharger or supercharger) before it enters theintake manifold and cylinders of the engine.

Turbo chargers compress air to increase power and efficiency. To furtherincrease power and meet emission standards, that air needs to be cooled.This hot air may contain large quantities of moisture vapor which, as itcondenses, contributes to corrosion, scale build-up, washing out oflubricant and possible freezing issues.

It would be desirable to provide an air cooler that reduces or overcomessome or all of the difficulties inherent in prior known devices.Particular advantages will be apparent to those skilled in the art, thatis, those who are knowledgeable or experienced in this field oftechnology, in view of the following disclosure of the invention anddetailed description of certain embodiments.

Particular objects and advantages of the invention will be apparent tothose skilled in the art, that is, those who are knowledgeable orexperienced in this field of technology, in view of the followingdisclosure of the invention and detailed description of certainpreferred embodiments.

SUMMARY

Aspects of the present invention may be used to advantageously providean air cooler with a water separator that improves the separation ofwater from the air stream before it enters the intake manifold andcylinders of an engine. The separation of water from the air stream mayalso be beneficial in other compressed air applications.

In accordance with a first aspect, an air cooler assembly includes anair cooler having an air inlet manifold, an air outlet manifold, and aheat exchanger core connected at a first end thereof to the air inletmanifold and at a second end thereof to the air outlet manifold. A waterseparator includes a chamber having a first end and an opposed secondend, an air inlet proximate the first end and connected to the airoutlet manifold, and an air outlet proximate the second end. A wateroutlet is formed in a bottom surface of the chamber, and a channel ispositioned beneath the water outlet. A condensate outlet is positionedon a bottom surface of the channel. A helical blade has a first end anda second end, and is positioned within the chamber between the air inletand the air outlet.

In accordance with another aspect, an air cooler assembly includes anair cooler having an air inlet manifold, an air outlet manifold, and aheat exchanger core connected at a first end thereof to the air inletmanifold and at a second end thereof to the air outlet manifold. A waterseparator assembly includes a chamber having a first end and an opposedsecond end, an air inlet proximate the first end and connected to theair outlet manifold and extending substantially vertically, and an airoutlet proximate the second end. The air outlet is formed of a firstportion extending downwardly and outwardly from the chamber and has afirst end positioned within the chamber and an opposed second end. Asecond portion is connected to the first end of the first portion andextends substantially horizontally. A water outlet including a pluralityof slots is formed in a bottom of the chamber. A channel is positionedbeneath the water outlet, and a condensate outlet extends downwardly andoutwardly from a bottom surface of the channel. A helical blade has afirst end and a second end, and is positioned within the chamber betweenthe air inlet and the air outlet. A first end surface of the helicalblade defines a first plane that extends substantially vertically withinthe chamber, and a second end surface defines a second plane thatextends substantially vertically within the chamber. An interior edge ofthe helical blade defines a central aperture that extends along alongitudinal axis of the chamber, and an exterior edge of the helicalblade extends along an interior surface of the chamber.

From the foregoing disclosure, it will be readily apparent to thoseskilled in the art, that is, those who are knowledgeable or experiencedin this area of technology, that preferred embodiments of an air cooleras disclosed herein provide a significant technological advance in termsof improved removal of condensed water. These and additional featuresand advantages will be further understood from the following detaileddisclosure of certain preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view, shown partially assembled, of anair cooler and a water separator connected to the air cooler.

FIG. 2 is a schematic perspective view, shown partially broken away, ofthe water separator connected to an air chamber outlet of the air coolerof FIG. 1 .

FIG. 3 is a side elevation view, partially in section, of the waterseparator and air chamber outlet of FIG. 1 .

FIG. 4 is an end elevation view, partially in section, of the waterseparator and air chamber outlet of FIG. 1 .

FIG. 5 is a rear perspective view, partially in section, of the waterseparator and air chamber outlet of FIG. 1 .

FIG. 6 is a schematic rear perspective view of the water separator andair chamber outlet of FIG. 1 .

The figures referred to above are not drawn necessarily to scale andshould be understood to provide a representation of the invention,illustrative of the principles involved. Some features of the air coolerdepicted in the drawings have been enlarged or distorted relative toothers to facilitate explanation and understanding. The same referencenumbers are used in the drawings for similar or identical components andfeatures shown in various alternative embodiments. Air coolers asdisclosed herein would have configurations and components determined, inpart, by the intended application and environment in which they areused.

DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS

The present invention may be embodied in various forms. An embodiment ofan air cooler 10 with a water separator 12 connected thereto is shown inFIG. 1 . Air cooler 10 may be a charge air cooler, for example. Aircooler 10 may be used, for example, to cool hot compressed airdischarged from an engine turbocharger before it enters the intakemanifold and cylinders of the engine. It is to be understood, however,that the air cooler is not limited to use in cooling hot air in engines,and may easily be used with fluids or gases in other fields.

For convenience, the terms “upper” and “lower” and “top” and “bottom”are used herein to differentiate between the upper and lower ends of theair cooler and particular elements. It is to be appreciated that “upper”and “lower” and “top” and “bottom” are used only for ease of descriptionand understanding and that they are not intended to limit the possiblespatial orientations of the air cooler or its components during assemblyor use.

Air cooler 10 may include an air chamber inlet 14 that allows heated airto be introduced into an inlet manifold 16. Heated air may then passfrom inlet manifold 16 through a heat exchanger core 17. In theillustrated embodiment, heat exchanger core 17 includes a plurality offlow tubes 18 with fins 19 on exterior surfaces thereof. For claritypurposes, only two finned flow tubes 18 are shown in FIG. 1 . It is tobe appreciated that other types of heat exchanger cores may be used tocool the heated air entering inlet manifold 16 through air inlet 14. Forexample, in certain embodiments, flow tubes 18 could be provided withoutfins. Other exemplary heat exchanger cores include U-tube, single passand double pass, and bar and plate heat exchanger cores. Other suitableheat exchanger cores will become readily apparent to those skilled inthe art, given the benefit of this disclosure.

Cool air may be directed in the direction of flow arrow F across anexterior of the plurality of finned flow tubes 18. It is to beappreciated that the flow of air across flow tubes may be created by afan (not shown), or by natural convection. It is also to be appreciatedthat the direction of flow arrow F can extend in any direction. The airflowing through finned tubes 18, which has been cooled by the airpassing over the exterior surfaces of finned flow tubes 18, may thenpass to an outlet manifold 21, and then from outlet manifold 21 on towater separator 12 through an air inlet 58 described below.

The cooled air leaving air cooler 10 by way of air outlet manifold 21and entering water separator 12 may include water, which, as notedabove, can be harmful to the engine. As the stream of air and waterpasses through water separator 12, the water may be removed, therebypreventing water from entering the engine.

Water separator 12 and its components may be formed of a non-corrosivematerial. Water separator may be formed of a resin or plastic, or ofmetal. Exemplary metals include aluminum and stainless steel. Othersuitable materials for water separator 12 will become readily apparentto those skilled in the art, given the benefit of this disclosure.

As illustrated in FIGS. 2-6 , water separator 12 may include a chamber50 having a first end 52, an opposed second end 54, and a sidewall 56extending between first end 52 and second end 54. In certainembodiments, chamber 50 may be substantially cylindrical incross-section.

The term “substantially”, as used herein, is meant to mean mostly, oralmost the same as, within the constraints of sensible commercialengineering objectives, costs, manufacturing tolerances, andcapabilities in the field of water separator manufacturing and use.Similarly, the term “approximately” as used herein is meant to meanclose to, or about a particular value, within the constraints ofsensible commercial engineering objectives, costs, manufacturingtolerances, and capabilities in the field of water separatormanufacturing and use.

An air inlet 58 may be positioned proximate first end 52 of chamber 50,and may be connected to outlet manifold 21 of air cooler 10 such thatchamber 50 is in fluid communication with heat exchanger core 17 aircooler 10. The cooled air passing out of heat exchanger core 17 throughoutlet manifold 21 may enter chamber 50 of water separator 12 throughair inlet 58. Air inlet 58 may be substantially cylindrical incross-section and may extend substantially vertically. It is to beappreciated that air inlet 58 may have any cross-sectional shape, andmay be oriented in any desired direction. In certain embodiments, asillustrated in FIG. 4 , a lower surface 60 of air inlet 58 may define aplane that is at an angle α with respect to longitudinal axis M of airinlet 58, which is oriented in a vertical direction in this embodiment.In certain embodiments, angle α may be approximately 45°, however, it isto be appreciated that angle α may have any value.

Chamber 50 may also include an air outlet 62 positioned proximate secondend 54, and air may exit chamber 50 through air outlet 62. In certainembodiments, air outlet 62 may be substantially cylindrical incross-section. It is to be appreciated that air outlet 62 may have anycross-sectional shape.

As seen in FIG. 5 , air outlet 62 may be formed of a first portion 64having a first end 65 and an opposed second end 67. First portion 64 mayextend from an interior of chamber 50 downwardly and outwardly throughsidewall 56. A longitudinal axis D of first portion 64 may extenddownwardly and outwardly at an angle β with respect to horizontal, asseen in FIG. 6 . In certain embodiments, angle β may be approximately45°. First end 65 of first portion 64 may be positioned within chamber50 and may define a plane that extends substantially vertically. Secondportion 66 may be connected to second end 67 of first portion 64 andextend substantially horizontally. It is to be appreciated that in otherembodiments, air outlet 62 may be formed of a single portion, and may beoriented at any desired angle.

A helical blade 66 may be positioned within chamber 50, and may have afirst end 68 and an opposed second end 70. First end 68 of helical blade66 may, in certain embodiments, be positioned downstream of air inlet58. In other embodiments, first end 68 may be positioned upstream of airinlet 58, while in other elements it may be positioned at air inlet 58.Second end 70 of helical blade 66 may, in certain embodiments, bepositioned upstream of air outlet 62. In other embodiments, second end70 may be positioned downstream of air outlet 62, while in otherelements it may be positioned at air outlet 62.

In certain embodiments, first end 68 of helical blade 66 may have afirst end surface 72 that extends substantially horizontally, anddefines a first plane that extends substantially vertically withinchamber 50. It is to be appreciated that in other embodiments first end68 may have any desired orientation. Similarly, second end 70 of helicalblade 66 may have a second end surface 74 that extends substantiallyhorizontally, and defines a second plane that extends substantiallyvertically within chamber 50. It is to be appreciated that in otherembodiments second end 70 may have any desired orientation.

Helical blade 60 may have a first surface 76, an opposed second surface78, an exterior edge 80 extending between first surface 76 and secondsurface 78 from first end 68 to second end 70, and an opposed interioredge 82 extending between first surface 76 and second surface 78 fromfirst end 68 to second end 70. In certain embodiments, exterior edge 80may be in contact with an interior surface 84 of chamber 50. Exterioredge 80 may be directly secured to interior surface 84 of chamber 50,such as by welding, for example. In certain embodiments, exterior edge80 may be spot or stitched welded at a plurality of points along itslength, while in other embodiments, exterior edge 80 may be welded alongan entirety of its length. As seen in FIG. 5 , interior edge 82 ofhelical blade 60 may define a substantially cylindrical central channel85 extending along an entire length of helical blade 60 coaxially withlongitudinal axis L of helical blade 60.

In the illustrated embodiment, first surface 76 and opposed secondsurface 78 of helical blade may be wound clockwise from first end 68toward second end 70. In other embodiments, first surface 76 and opposedsecond surface 78 of helical blade may be wound counterclockwise fromfirst end 68 toward second end 70. In certain embodiments, each ofexterior edge 80 and interior edge 82 of helical blade 60 may complete afull revolution between first end 68 and second end 70 of helical blade60. It is to be appreciated that in other embodiments, exterior edge 80and interior edge 82 may complete more or less than a full revolutionbetween first end 68 and second end 70 of helical blade 60.

A water outlet 86 may be positioned at a bottom of chamber 50 proximatesecond end 74 of helical blade 66 and proximate air outlet 62, andserves to allow water to drain from chamber 50. In certain embodiments,water outlet 86 may be in the form of a plurality of apertures or slots88 extending through sidewall 56, which allow water to drain out ofchamber 50. In certain embodiments, slots 88 may be racetrack shaped.Slots 88 may be collinear and have a common longitudinal axis S thatextends substantially parallel to a longitudinal axis L of chamber 50.It is to be appreciated that water outlet 86 can take any desired formincluding, for example, a screen or a perforated plate.

A gutter or channel 90 may be secured to a bottom of chamber 50 beneathgrate 86. Channel 90 may have a substantially cylindrical cross-sectionin certain embodiments, with a longitudinal axis A that extendssubstantially parallel to longitudinal axis L of chamber 50. It is to beappreciated that channel 90 may have any desired cross-sectional shape.

A condensate outlet 92 may be connected to an outlet opening 94 on abottom of channel 90, allowing water to be drained out of channel 90. Incertain embodiments, condensate outlet 92 may have a substantiallycylindrical cross-section. It is to be appreciated that condensateoutlet 92 may have any desired cross-sectional shape.

As illustrated in FIG. 3 , in certain embodiments, air outlet 62 may bepositioned along longitudinal axis L of chamber 50 proximate a midpointof grate 86, and channel 90.

As the heated air moves through chamber 50, it is redirected by helicalblade 66, helping to remove moisture from the air. As the air movesalong the surface of helical blade 66 and through central aperture 85,the heavier drops of moisture fall off the interior edge 82 of helicalblade 66, and pass through water outlet 86 into channel 90.

As seen in FIGS. 4 and 6 , air inlet 58 may be positioned with chamber50 such that its longitudinal axis M is spaced from longitudinal axis Lof chamber 50 and proximate sidewall 56, which helps introduce spin tothe air flowing into chamber 50, directing it along sidewall 56 andalong helical blade 66.

As seen in FIG. 4 , first end 65 of first portion 64 of air outlet 62may be positioned in a central portion of chamber 50 proximatelongitudinal axis L, which can help prevent moisture from chamber 50entering air outlet 62 as the air leaves chamber 50.

Thus, while there have been shown, described, and pointed outfundamental novel features of various embodiments, it will be understoodthat various omissions, substitutions, and changes in the form anddetails of the devices illustrated, and in their operation, may be madeby those skilled in the art without departing from the spirit and scopeof the invention. For example, it is expressly intended that allcombinations of those elements and/or steps which perform substantiallythe same function, in substantially the same way, to achieve the sameresults are within the scope of the invention. Substitutions of elementsfrom one described embodiment to another are also fully intended andcontemplated. It is the intention, therefore, to be limited only asindicated by the scope of the claims appended hereto.

What is claimed is:
 1. An air cooler assembly comprising: an air cooler including an air inlet manifold, an air outlet manifold, and a heat exchanger core connected at a first end thereof to the air inlet manifold and at a second end thereof to the air outlet manifold; and a water separator assembly comprising: a chamber having a first end and an opposed second end, an air inlet proximate the first end and connected to the air outlet manifold, and an air outlet proximate the second end; a water outlet formed in a bottom surface of the chamber; a helical blade having a first end and a second end, and positioned within the chamber between the air inlet and the air outlet; and a channel positioned beneath the water outlet and a condensate outlet on a bottom surface of the channel, the air outlet being positioned along a longitudinal axis of the chamber proximate a midpoint of a length of the channel.
 2. The air cooler assembly of claim 1, wherein the first end of the helical blade is downstream of the air inlet, the second end of the helical blade is upstream of the air outlet.
 3. The air cooler assembly of claim 1, wherein the condensate outlet extends downwardly and outwardly from the channel.
 4. The air cooler assembly of claim 1, wherein the air inlet extends substantially vertically.
 5. The air cooler assembly of claim 4, wherein a longitudinal axis of the air inlet is spaced from a longitudinal axis of the chamber and is proximate a sidewall of the chamber.
 6. The air cooler assembly of claim 1, wherein the air inlet comprises a cylinder extending substantially vertically, a bottom surface of the cylinder defining a plane that is at an angle of approximately 45° with respect to vertical.
 7. The air cooler assembly of claim 1, wherein the air outlet comprises: a first portion having a first end positioned in the chamber and a second end, and extending downwardly and outwardly from the chamber; and a second portion extending horizontally from the second end of the first portion.
 8. The air cooler assembly of claim 7, wherein the first end is positioned in a central portion of the chamber proximate a longitudinal axis of the chamber.
 9. The air cooler assembly of claim 1, wherein each of a first edge and an opposed second edge of the helical blade completes a full revolution between the first end of the helical blade and the second end of the helical blade.
 10. The air cooler assembly of claim 1, wherein a surface of the helical blade is wound clockwise from the first end of the helical blade to the second end of the helical blade.
 11. The air cooler assembly of claim 1, wherein an exterior edge of the helical blade is in contact with an interior surface of the chamber.
 12. The air cooler assembly of claim 11, wherein the exterior edge of the helical blade is secured to the interior surface of the chamber.
 13. The air cooler assembly of claim 1, wherein an interior edge of the helical blade defines a cylindrical central channel extending longitudinally along the chamber.
 14. The air cooler assembly of claim 1, wherein the water outlet comprises a plurality of slots formed in a bottom of the chamber.
 15. The air cooler assembly of claim 14, wherein each of the slots has a longitudinal axis, the longitudinal axis of each of the slots being collinear with one another and with a longitudinal axis of the chamber.
 16. The air cooler assembly of claim 1, wherein the chamber has a cylindrical cross-section.
 17. The air cooler assembly of claim 1, wherein the helical blade includes a first end surface that extends substantially horizontally, and defines a first plane that extends substantially vertically within the chamber, and a second end surface that extends substantially horizontally, and defines a second plane that extends substantially vertically within the chamber.
 18. An air cooler water separator assembly comprising: an air cooler including an air inlet manifold, an air outlet manifold, and a heat exchanger core connected at a first end thereof to the air inlet manifold and at a second end thereof to the air outlet manifold; and a water separator assembly comprising: a chamber having a first end and an opposed second end, an air inlet proximate the first end and connected to the air outlet manifold and extending substantially vertically, and an air outlet proximate the second end, the air outlet formed of a first portion extending downwardly and outwardly from the chamber and having a first end positioned within the chamber and an opposed second end, and a second portion connected to the first end of the first portion and extending substantially horizontally; a water outlet including a plurality of slots formed in a bottom surface of the chamber; a channel positioned beneath the water outlet; a condensate outlet extending downwardly and outwardly from a bottom surface of the channel; and a helical blade having a first end and a second end, and positioned within the chamber between the air inlet and the air outlet, wherein a first end surface of the helical blade defines a first plane that extends substantially vertically within the chamber, a second end surface defines a second plane that extends substantially vertically within the chamber, an interior edge of the helical blade defines a central aperture that extends along a longitudinal axis of the chamber, and an exterior edge of the helical blade extends along an interior surface of the chamber. 